Apparatus and method for dispensing objects to a count and/or weight

Abstract

An apparatus for dispensing a predetermined count and/or weight of objects into a receptacle includes a conveyor, an object sensor, a controller, a trickle-feed conveyor, and a receptacle conveyor. The conveyor conveys the objects and has at least one grouping assembly which is capable of capturing a group of objects and supporting that group of objects during conveyance. The object sensor is disposed to detect the presence of each of the groups of objects prior to discharge and relays information relating to the number of objects within each group of objects. The controller communicates with the object sensor, monitors the information relayed, generates instructions, and tracks the location of each grouping assembly from detection to discharge into the receptacle. The controller also monitors the number of objects in each group of objects discharged into the receptacle. The trickle-feed conveyor conveys objects for discharge one at a time into the receptacle in response to instructions received from the controller. The receptacle conveyor positions the receptacle in the proximity of the conveyor in response to instructions received from the controller so that the receptacle receives objects from the groups of objects discharged from the conveyor up to but not exceeding the predetermined count or weight of objects. The receptacle conveyor also moves the receptacle from the proximity of the conveyor to the proximity of the trickle-feed conveyor so that the receptacle can receive objects discharged from the trickle-feed conveyor until the receptacle has received the predetermined count or weight of objects.

What is claimed and desired to be secured by United States Letters Patent is: 
     
       1. An apparatus for dispensing a predetermined count of objects into a receptacle, comprising: a conveyor for conveying objects, said conveyor comprising a plurality of elongate cylindrical rollers connected in an endless belt configuration, said conveyor having at least one grouping assembly, each said grouping assembly capable of capturing a group of objects and supporting that group of objects during conveyance until that group of objects is discharged into the receptacle, each said grouping assembly comprising a pair of adjacent said cylindrical rollers disposed to support thereupon objects during conveyance, wherein the adjacent pairs of said cylindrical rollers in each grouping assembly are spaced so that there is a gap through which light may pass between said cylindrical rollers and said cylindrical rollers have a length greater than the width of at least two of objects placed side by side so that each grouping assembly is capable of supporting during conveyance at least two objects;   an object sensor disposed in sensory communication with said conveyor for detecting the presence of one of the groups of objects prior to discharge and relaying information relating to the number of objects within that group of objects;   a controller in communication with said object sensor for monitoring information relayed from said object sensor and for generating instructions, said controller being capable of tracking the location of each grouping assembly conveying one of the groups of objects from detection to discharge into the receptacle and monitoring the number of objects in each group of objects discharged into the receptacle so that the receptacle receives objects from the groups of objects discharged from the conveyor up to but not exceeding the predetermined count of objects; and   a trickle-feed conveyor in communication with said controller and capable of conveying objects for discharge one at a time into the receptacle in response to instructions received from said controller, said trickle-feed conveyor discharges objects into the receptacle until the receptacle has received the predetermined count of objects.   
     
     
       2. An apparatus as set forth in claim 1, further comprising an accumulator disposed to receive groups of objects discharged from said conveyor and for directing the objects into the receptacle. 
     
     
       3. An apparatus as set forth in claim 2, wherein said accumulator comprises a hopper and a rotatable cylindrical brush, said hopper having a mouth for receiving discharged objects, a neck for gathering the objects, and an opening through which the objects are directed into the receptacle, said cylindrical brush being disposed to obscure passage through said opening unless said cylindrical brush is rotated. 
     
     
       4. An apparatus as set forth in claim 2, wherein said accumulator comprises a hopper and a pair of rotatable cylindrical brushes, said hopper having a mouth for receiving discharged objects, a neck for gathering the objects, and an opening through which the objects are directed into the receptacle, said pair of cylindrical brushes having parallel axes of rotation and being disposed adjacent each other to obscure passage through said opening unless said cylindrical brushes are rotated in opposite directions so that objects may pass between said pair of cylindrical brushes. 
     
     
       5. An apparatus as set forth in claim 4, wherein said pair of cylindrical brushes is in communication with said controller and responsive to instructions from said controller, said pair of cylindrical brushes rotates and pauses rotation thereby permitting objects to pass into the receptacle by passing between said pair of cylindrical brushes during rotation, and if rotation is paused, permitting objects to accumulate within said hopper until rotation is recommenced. 
     
     
       6. An apparatus as set forth in claim 1, further comprising a trickle-feed chute for directing objects from discharge from said trickle-feed conveyor into the receptacle. 
     
     
       7. An apparatus as set forth in claim 1, wherein said controller comprises a microprocessor. 
     
     
       8. An apparatus as set forth in claim 1, wherein said object sensor comprises a light emitter and a light detector, said light emitter being disposed in light communication with said light detector and adjacent said conveyor such that said light emitter emits light through said gap of one of said grouping assemblies for detection by said light detector when that grouping assembly passes between said light emitter and said light detector, said light detector also capable of detecting the absence of light in said gap if objects are being conveyed by said grouping assembly as said grouping assembly passes between said light emitter and said light detector. 
     
     
       9. An apparatus as set forth in claim 8, wherein said object sensor further comprises an encoder for determining when one of said gaps is disposed between said light emitter and said light detector and communicating the presence of said gap so that said light detector interrogates said gap for the presence of light and said controller is relayed the information for monitoring the number of objects being conveyed by said grouping assembly corresponding to said gap. 
     
     
       10. An apparatus as set forth in claim 8, wherein said light detector is a line scan camera. 
     
     
       11. An apparatus as set forth in claim 1, wherein said conveyor further comprises a clutch for pausing the conveyance of objects and for pausing the discharge of objects into the receptacle. 
     
     
       12. An apparatus for dispensing a predetermined count of objects into a receptacle, comprising: a conveyor for conveying objects having at least one grouping assembly, each said grouping assembly capable of capturing a group of objects and supporting that group of objects during conveyance until that group of objects is discharged into the receptacle;   an object sensor disposed in sensory communication with said conveyor for detecting the presence of one of the groups of objects prior to discharge and relaying information relating to the number of objects within that group of objects;   a controller in communication with said object sensor for monitoring information relayed from said object sensor and for generating instructions, said controller being capable of tracking the location of each grouping assembly conveying one of the groups of objects from detection to discharge into the receptacle and monitoring the number of objects in each group of objects discharged into the receptacle so that the receptacle receives objects from the groups of objects discharged from the conveyor up to but not exceeding the predetermined count of objects; and   a trickle-feed conveyor in communication with said controller and capable of conveying objects for discharge one at a time into the receptacle in response to instructions received from said controller, said trickle-feed conveyor discharges objects into the receptacle until the receptacle has received the predetermined count of objects, wherein said trickle-feed conveyor comprises a plurality of rollers connected in an endless belt configuration and defining a plurality of conveying pockets between adjacent pairs of rollers, each said conveying pocket being capable of supporting one of the objects during conveyance.   
     
     
       13. An apparatus as set forth in claim 12, wherein each roller has a length which is less than the width of two of the objects placed side by side so that each conveying pocket is capable of conveying only a single object. 
     
     
       14. An apparatus as set forth in claim 13, further comprising a detector disposed adjacent said trickle-feed conveyor for detecting the presence of one of the objects within each conveying pocket as each conveying pocket passes said detector. 
     
     
       15. An apparatus as set forth in claim 14, wherein said detector further comprises a trickle-feed encoder for determining the presence of one of said conveying pockets at the detector so that said detector is interrogated regarding the presence of one of the objects enabling said controller to monitor the number of objects for discharge into the receptacle. 
     
     
       16. An apparatus as set forth in claim 14, wherein said detector comprises a light source and a light sensor. 
     
     
       17. An apparatus for dispensing a predetermined count of objects into a receptacle, comprising: a conveyor for conveying objects having at least one grouping assembly, each said grouping assembly capable of capturing a group of objects and supporting that group of objects during conveyance until that group of objects is discharged into the receptacle;   an object sensor disposed in sensory communication with said conveyor for detecting the presence of one of the groups of objects prior to discharge and relaying information relating to the number of objects within that group of objects;   a controller in communication with said object sensor for monitoring information relayed from said object sensor and for generating instructions, said controller being capable of tracking the location of each grouping assembly conveying one of the groups of objects from detection to discharge into the receptacle and monitoring the number of objects in each group of objects discharged into the receptacle so that the receptacle receives objects from the groups of objects discharged from the conveyor up to but not exceeding the predetermined count of objects; and   a trickle-feed conveyor in communication with said controller and capable of conveying objects for discharge one at a time into the receptacle in response to instructions received from said controller, said trickle-feed conveyor discharges objects into the receptacle until the receptacle has received the predetermined count of objects, wherein said trickle-feed conveyor comprises a clutch for pausing the conveyance of objects after the receptacle is filled to the predetermined count of objects.   
     
     
       18. A method for determining the average weight of the objects contained within each receptacle filled to a predetermined weight, comprising the steps of: (a) supplying objects to a conveyor having at least one grouping assembly capable of supporting more than one object during conveyance;   (b) positioning the receptacle in the proximity of the conveyor so that the receptacle receives objects discharged from the conveyor;   (c) capturing a group of objects for supported conveyance on one of the grouping assemblies and conveying that group of objects to discharge into the receptacle;   (d) detecting the presence of objects within the group of objects;   (e) relaying information relating to the number of objects within the group of objects to a controller;   (f) monitoring the number of objects in each group of objects conveyed for discharge into the receptacle;   (g) tracking the location of each group of objects from detection to discharge into the receptacle;   (h) counting the number of objects discharged into the receptacle;   (i) pausing further discharge of objects into the receptacle if the next group of objects to discharge objects into the receptacle contains a number of objects that would cause the count to exceed a predetermined count of objects;   (j) moving the receptacle from the proximity of the conveyor to the proximity of a trickle-feed conveyor so that the receptacle can receive objects discharged from the trickle-feed conveyor;   (k) conveying objects on the trickle-feed conveyor for discharge one at a time into the receptacle until the contents of the receptacle weighs the predetermined weight and further discharge is ceased;   (l) weighing the contents of the receptacle after further discharge of objects one at a time into the receptacle is ceased;   (m) determining the count of objects within the receptacle after further discharge of objects one at a time into the receptacle is ceased; and   (n) dividing the weight determined from step (l) by the count of objects determined from step (m).   
     
     
       19. A method as set forth in claim 18, further comprising the steps of monitoring the number of objects required to fill the receptacle to the predetermined weight over time and adjusting the predetermined count so that the adding of objects one at a time is minimized. 
     
     
       20. An apparatus for dispensing a predetermined count of objects into a receptacle, comprising: a conveyor for conveying objects having at least one grouping assembly, each said grouping assembly capable of capturing a group of objects and supporting that group of objects during conveyance until that group of objects is discharged into the receptacle;   an object sensor disposed in sensory communication with said conveyor for detecting the presence of one of the groups of objects prior to discharge and relaying information relating to the number of objects within that group of objects;   a controller in communication with said object sensor for monitoring information relayed from said object sensor and for generating instructions, said controller being capable of tracking the location of each grouping assembly conveying one of the groups of objects from detection to discharge into the receptacle and monitoring the number of objects in each group of objects discharged into the receptacle;   a trickle-feed conveyor in communication with said controller and capable of conveying objects for discharge one at a time into the receptacle in response to instructions received from said controller; and   a receptacle conveyor in communication with said controller, said receptacle conveyor for positioning the receptacle in the proximity of said conveyor in response to instructions received from said controller so that the receptacle receives objects from groups of objects discharged from the conveyor up to but not exceeding the predetermined count of objects, said receptacle conveyor also being capable of moving the receptacle from the proximity of said conveyor to the proximity of said trickle-feed conveyor so that the receptacle can receive objects discharged from the trickle-feed conveyor until the receptacle has received the predetermined count of objects, said receptacle conveyor further comprises a load cell disposed beneath and supporting the receptacle if the receptacle is positioned in the proximity of said trickle-feed conveyor for weighing the objects contained within the container when the receptacle is filled to the predetermined count of objects.   
     
     
       21. A method for determining the average weight of the objects contained within each receptacle filled to a predetermined count, comprising the steps of: (a) supplying objects to a conveyor having at least one grouping assembly capable of supporting more than one object during conveyance;   (b) positioning the receptacle in the proximity of the conveyor so that the receptacle receives objects discharged from the conveyor;   (c) capturing a group of objects for supported conveyance on one of the grouping assemblies and conveying that group of objects to discharge into the receptacle;   (d) detecting the presence of objects within the group of objects;   (e) relaying information relating to the number of objects within the group of objects to a controller;   (f) monitoring the number of objects in each group of objects conveyed for discharge into the receptacle;   (g) tracking the location of each group of objects from detection to discharge into the receptacle;   (h) counting the number of objects discharged into the receptacle;   (i) pausing further discharge of objects into the receptacle if the next group of objects to discharge objects into the receptacle contains a number of objects that would cause the count to exceed the predetermined count of objects;   (j) moving the receptacle from the proximity of the conveyor to the proximity of a trickle-feed conveyor so that the receptacle can receive objects discharged from the trickle-feed conveyor;   (k) conveying objects on the trickle-feed conveyor for discharge one at a time into the receptacle until the receptacle has received the predetermined count of objects;   (l) weighing the objects within the receptacle after the receptacle has received the predetermined count of objects; and   (m) dividing the weight determined from step (l) by the predetermined count of objects.   
     
     
       22. An apparatus for rough-filling a receptacle with objects up to but not exceeding a predetermined count of objects, comprising: a conveyor for conveying objects, said conveyor comprising a plurality of elongate cylindrical rollers connected in an endless belt configuration, said conveyor having at least one grouping assembly, each said grouping assembly capable of capturing a group of objects and supporting that group of objects during conveyance until that group of objects is discharged into the receptacle, each said grouping assembly comprising a pair of adjacent said cylindrical rollers disposed to support thereupon objects during conveyance, wherein the adjacent pairs of said cylindrical rollers in each grouping assembly are spaced so that there is a gap through which light may pass between said cylindrical rollers and said cylindrical rollers have a length greater than the width of at least two of objects placed side by side so that each grouping assembly is capable of supporting during conveyance at least two objects;   an object sensor disposed in sensory communication with said conveyor for detecting the presence of one of the groups of objects prior to discharge and relaying information relating to the number of objects within that group of objects; and   a controller in communication with said object sensor for monitoring information relayed from said object sensor and for generating instructions, said controller being capable of tracking the location of each grouping assembly conveying one of the groups of objects from detection to discharge into the receptacle and monitoring the number of objects in each group of objects discharged into the receptacle so that the receptacle receives objects from the groups of objects discharged from the conveyor up to but not exceeding the predetermined count of objects.   
     
     
       23. An apparatus as set forth in claim 22, further comprising an accumulator disposed to receive groups of objects discharged from said conveyor and for directing the objects into the receptacle. 
     
     
       24. An apparatus as set forth in claim 23, wherein said accumulator comprises a hopper and a rotatable cylindrical brush, said hopper having a mouth for receiving discharged objects, a neck for gathering the objects, and an opening through which the objects are directed into the receptacle, said cylindrical brush being disposed to obscure passage through said opening unless said cylindrical brush is rotated. 
     
     
       25. An apparatus as set forth in claim 23, wherein said accumulator comprises a hopper and a pair of rotatable cylindrical brushes, said hopper having a mouth for receiving discharged objects, a neck for gathering the objects, and an opening through which the objects are directed into the receptacle, said pair of cylindrical brushes having parallel axes of rotation and being disposed adjacent each other to obscure passage through said opening unless said cylindrical brushes are rotated in opposite directions so that objects may pass between said pair of cylindrical brushes. 
     
     
       26. An apparatus as set forth in claim 25, wherein said pair of cylindrical brushes is in communication with said controller and responsive to instructions from said controller, said pair of cylindrical brushes rotates and pauses rotation thereby permitting objects to pass into the receptacle by passing between said pair of cylindrical brushes during rotation, and if rotation is paused, permitting objects to accumulate within said hopper until rotation is recommenced. 
     
     
       27. An apparatus as set forth in claim 22, wherein said conveyor further comprises a clutch for pausing the conveyance of objects and for pausing the discharge of objects into the receptacle. 
     
     
       28. An apparatus as set forth in claim 22, wherein said controller comprises a microprocessor. 
     
     
       29. An apparatus as set forth in claim 22, wherein said object sensor comprises a light emitter and a light detector, said light emitter being disposed in light communication with said light detector and adjacent said conveyor such that said light emitter emits light through said gap of one of said grouping assemblies for detection by said light detector when that grouping assembly passes between said light emitter and said light detector, said light detector also capable of detecting the absence of light in said gap if objects are being conveyed by said grouping assembly as said grouping assembly passes between said light emitter and said light detector. 
     
     
       30. An apparatus as set forth in claim 29, wherein said object sensor further comprises an encoder for determining when one of said gaps is disposed between said light emitter and said light detector and communicating the presence of said gap so that said light detector interrogates said gap for the presence of light and said controller is relayed the information for monitoring the number of objects being conveyed by said grouping assembly corresponding to said gap. 
     
     
       31. An apparatus as set forth in claim 29, wherein said light detector is a line scan camera. 
     
     
       32. A method for counting objects dispensed into a receptacle so that the receptacle is rough-filled up to but not exceeding a predetermined count of objects, comprising the steps of: (a) supplying objects to a conveyor having at least one grouping assembly capable of supporting more than one object during conveyance;   (b) capturing a group of objects for conveyance and conveying that group of objects to discharge into the receptacle;   (c) detecting the presence of objects within the group of objects;   (d) relaying information relating to the number of objects within the group of objects to a controller;   (e) monitoring the number of objects in each group of objects conveyed for discharge into the receptacle;   (f) tracking the location of each group of objects from detection to discharge into the receptacle;   (g) counting the number of objects discharged into the receptacle; and   (h) pausing further discharge of objects into the receptacle if the next group of objects to discharge objects into the receptacle contains a number of objects that would cause the count to exceed the predetermined count of objects.   
     
     
       33. A method for dispensing objects into a receptacle so that the contents of the receptacle weighs a predetermined weight and the number of objects is determined, comprising the steps of: (a) supplying objects to a conveyor having at least one grouping assembly capable of supporting more than one object during conveyance;   (b) capturing a group of objects for conveyance and conveying that group of objects to discharge into the receptacle;   (c) detecting the presence of objects within the group of objects;   (d) relaying information relating to the number of objects within the group of objects to a controller;   (e) monitoring the number of objects in each group of objects conveyed for discharge into the receptacle;   (f) tracking the location of each group of objects from detection to discharge into the receptacle;   (g) counting the number of objects discharged into the receptacle;   (h) pausing further discharge of objects into the receptacle if the next group of objects to discharge objects into the receptacle contains a number of objects that would cause the count to exceed a predetermined count of objects;   (i) adding objects one at a time to the contents of the receptacle until the weight of the contents of the receptacle weighs a predetermined weight; and   (j) counting each object added one at a time to determine the number of objects contained within the receptacle when the predetermined weight of the contents is achieved.   
     
     
       34. A method as set forth in claim 33, further comprising the steps of monitoring the number of objects required to fill the receptacle to the predetermined weight over time and adjusting the predetermined count so that the adding of objects one at a time is minimized.